Hydro-formed film with three-dimensional micro-apertures

ABSTRACT

A hydro-formed film includes a polymeric web having a first substantially planar surface and a second substantially planar surface opposite the first substantially planar surface, and a plurality of three-dimensional micro-apertures extending from the first substantially planar surface. The plurality of three-dimensional micro-apertures have a mesh count in a range of about 40 to about 75 apertures per linear inch. The hydro-formed film has a Compression Sensor Point (CSP) count of at least about 80.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 15/374,567, filed Dec. 9, 2016, currently pending,which claims the benefit of priority from U.S. Provisional PatentApplication No. 62/266,256, filed Dec. 11, 2015, the contents of both ofwhich are incorporated herein by reference in their entireties.

FIELD

The present invention relates generally to porous polymeric films usefulin absorptive devices for the transmission of fluids. In particular, thepresent invention relates to films with three-dimensionalmicro-apertures in patterns of high mesh count of greater than 30 meshwhich provide softness while also helping to reduce surface wetnessafter use.

BACKGROUND

Three-dimensional apertured formed film topsheets, or the acquisitiondistribution layer interposed between the topsheet and the core ofabsorptive devices, having both three-dimensional micro-apertures facingupward toward the skin side of users of absorptive devices andthree-dimensional macro-apertures interspersed in a pattern within thefield of three-dimensional micro-apertures, the macro-apertures facingdownward toward the absorbent core, are well known in the art. Thethree-dimensional micro-apertures are known to provide a tactileimpression of cottony soft, cloth-like or silky textures while alsoenhancing the reduction of the amount of surface wetness after use.

Such films may be produced using one of several methods, includingvacuum-forming process and hydro-forming process. In both these methods,the film is deposited on a rotating screen having openings correspondingto a desired micro-aperture pattern. In vacuum-forming, a relativevacuum is established across the screen so that the film is drawn intothe openings, thereby forming a series of protrusions on the filmsurface. If the vacuum differential is sufficient, an opening is formedin the film at the apex of each protrusion. In hydro-forming, similarprotrusions are formed by directing a high pressure water stream at theside of the film opposite of the screen. The pressure of the waterstream forces the film into the holes of the screen. If sufficientpressure is applied, an opening is formed in the film at the apex ofeach protrusion.

Micro-apertures can also be formed using mechanical methods such asneedle punching, but such methods tend to require additional steps toprovide the three dimensionality that tends to enhance the perceivedsoftness of the final material.

In U.S. Pat. No. 4,609,518 to Curro et al. (“Curro '518”), a polymericweb can be produced using one or more three-dimensional formingstructures, essentially a parent patent to the “hydro-forming process”,it is taught that three-dimensional micro-aperture patterns of high meshcount are formed by a high pressure water stream “. . . having filaments[or lands]. . . ranging in diameter [or land width] from about 3 mils toabout 7 mils and mesh counts ranging from about 140 by 140 per squareinch to about 80 by 80 per square inch, respectively, will typicallyproduce very soft feeling three-dimensional apertured webs whensubjected to the high pressure liquid jet[s]. . . issuing fromnozzle[s]. . . . The relatively small three-dimensional aperturescreated in such webs substantially correspond to the void spaces [oropenings] created in the interstices. . . between the intersectingfilaments [or lands].” The three-dimensional macro-apertures are thenformed in a second stage process where that forming screen has largeopenings of a lower mesh count as designed to be suitable for adequatefluid acquisition through the topsheet into the absorbent core ofabsorptive device.

Premium ALWAYS® brand feminine hygiene pads, sold by Procter & GambleCo., OH, utilize a topsheet substantially produced by the hydroformingprocess of Curro '518. The three-dimensional micro-aperture pattern,when counted from a purchased pad from any of a variety of RetailStores, is generally around 100 mesh. It is known for its cottony softtactile impression which renders both comfort and cleanliness to theuser. When viewing the three-dimensional micro-apertures undermagnification they have an elongation, or major axis, in the machinedirection (MD). The MD corresponds to the length or front-to-backdirection of the feminine pad. Many are somewhat pointed at theirextreme ends of their major axis. They appear in shape to be verysimilar to the iris of a ‘cat-eye’, thus here-in-after their shape willbe known as a ‘cat-eye’ shape. This cat-eye shape is common forthree-dimensional apertures formed in the hydroforming process of theprior art.

Three-dimensional macro-apertures can be formed into a ‘precursor’ webalready comprising a pattern of softening three-dimensionalmicro-apertures. A second stage of hydroforming is used in Curro '518.Other methods use a roller with a pattern of needles, pins or similarprotrusions with the protrusions being pushed through the precursor webinto a malleable, easily penetrated material, or, ideally, into acorresponding pattern of depression such as grooves, slots or cavities.Typically the protruding direction of the micro-apertures is up and theprotruding direction of the macro-apertures is down.

U.S. Pat. No. 8,168,102 to Di Berardino (“Di Berardino '102”) disclosesone mechanical punching method. In its abstract it describes: “A machineutilized for producing and manufacturing a film, soft at touch,resilient and suitable at draining use. A film produced by such amachine, presents, at least, on one surface an essentially continuouspattern of micro-funnels three-dimensional (3D) directed in anessentially perpendicular way to the surface from which themicro-openings have origin. It presents also on the opposite surface acontinuous pattern, composed by 3D macro-funnels directed in anessentially perpendicular way to the surface from which themacro-funnels have origin. The “micro-funnels” term, intend to describea multitude of funnels non-distinguishable by the human eye at adistance equal or higher than 450 mm, while the “macro-funnels” term,intend to describe funnels clearly visible by the human eye at adistance higher than 450 mm.”

Claim 9 of Di Berardino '102 further describes the method: “A device forforming a thermoplastic film with macro holes from a film already havingmicro holes, comprising: a first reel with multiple needles on itssurface; a second reel with multiple grooves, the grooves coupled to theneedles during the rotation of the first and second reels to obtain themacro holes; and a third reel with perforations, the perforations beingcoupled with the needles of the first reel during rotation of the firstreel to remove the thermoplastic film from the first reel withoutsubstantially damaging the micro holes, wherein the third reel useselectrostatic electricity to remove the thermoplastic film from thefirst reel by exerting a force via the electrostatic electricity on themacro holes of the thermoplastic film.”

U BY KOTEX® brand feminine napkins, sold by Kimberly-Clark Corporation,utilize this type of topsheet material and call it an Xpress DRI® cover.The three-dimensional micro-aperture pattern, when counted from apurchased pad from any of a variety of Retail Stores, is generallyaround 60 mesh. It is also known for its cottony soft tactile impressionwhich renders both comfort and cleanliness to the user. When viewing thethree-dimensional micro-apertures under magnification they areessentially round, as is common for three-dimensional apertures formedin a vacuum forming process.

Additionally, it is known that sufficient open area of thethree-dimensional micro-apertured web, as with any three-dimensionalapertured web, is required not only for adequate softness but also toassist with fluid acquisition related to surface cleanliness after use.While the 100 mesh hydroformed pattern is proven to be sufficiently softand clean, 100 mesh to about 75 mesh patterns will not form goodthree-dimensional aperture openings by the vacuum forming method due toits limited maximum pressure differential of slightly less than onenegative atmosphere—about 14.0 PSI. Smaller openings require higherforce to create an opening like the multiple hundreds PSI ofhydro-forming. Therefore, the film's open area achievable by vacuumforming, virtually approaching zero percent as mesh counts increasebeyond 75 mesh, is insufficient for good performance in reducingresidual surface wetness after use. The smaller opening sizes and lackof thinning at the apex can also negatively affect the perception ofsoftness.

Conversely, the lower mesh count versions in the range ofmicro-apertures from about 40 to about 75 mesh, that form good roundopenings with sufficient open area in the vacuum forming process, willnot form openings with sufficient open area for fluid acquisitiondynamics or sufficient softness properties when produced by thehydroforming process. Logically the cat-eye shape of hydroforming,increasingly more dramatic within these micro-aperture mesh counts,where the forming screens have progressively larger openings, reducesthe resulting film's open area. While a circle's major axis (i.e., itsdiameter) exists in all directions, the cat-eye shape (which may be anellipse or other ovate figure) has a major axis value and a minor axisvalue in the other direction. Thus, the cat-eye shape has a loweropening area than a circle having the same major axis value.Hydro-forming also creates a smaller aperture in general, so its majoraxis will be less than the value of the circle's axis, which compoundsthe loss of open area.

This difference occurs primarily because in vacuum forming methods thepolymer web is provided in molten form, and is therefore completelypliable and formable. As a result, the pressure differential due to thevacuum causes the molten material to mold itself against the walls ofthe aperture. In that last moment of being molten, it essentially formsan exact replicate of the screen aperture. As it cools to a solid state,however, it shrinks. This shrinkage reduces the film aperture dimensionsto only a percentage of the screen aperture dimensions.

Conversely, hydro-forming processes involve placing a solid (i.e.,non-molten) film web over the forming screen. Such a web requires ahigher pressure differential to distort and re-shape the solid film intoits new three dimensional aperture form. The film is not molded, as isthe molten web of vacuum forming, but rather is stretched and distortedor deformed by pressure; hence, the cat-eye shape results as seen in thehigher mesh counts needed for softness.

The hydro-forming film's resulting cat-eye is also the cause of the poorsoftness properties. It was therefore necessary to invent athree-dimensional micro-apertured film in the lower micro-aperturedrange of mesh counts from about 40 to about 75 produced by thehydroforming method that would create substantially round openings,where some would have soft petals at their apex, in order to achieveadequate fluid acquisition and improved, even superior, softnessproperties.

Each of the above forming methods have certain advantages in regard tothe final product. The methods of the present invention provide acombination of these advantages.

SUMMARY

An illustrative aspect of the present invention provides a method ofprocessing a polymeric web having a substantially planar surface. Themethod comprises providing a forming screen configured for supportingand moving with the web in a machine direction. The forming screen has ascreen wall with a plurality of elliptical screen openings formedtherethrough. Each screen opening has a major axis dimensionperpendicular to the machine direction and a minor axis dimensionparallel to the machine direction. The method further comprisescontinuously depositing the web onto the forming screen so that the webis supported by the screen wall and so that the web and the formingscreen wall move together in the machine direction. The web and formingscreen wall are passed through a water stream having a pressure levelsufficient to cause the web to be forced into the screen openings. Thisforms localized protrusions extending from the planar surface of theweb, each protrusion having an apex, an opening at the apex, and anelliptical cross-section parallel to the planar surface of the web. Theelliptical cross-section has a protrusion axis ratio. In particularembodiments, the screen opening axis ratio is selected so as to producea desired protrusion axis ratio.

Another illustrative aspect of the invention provides a film comprisinga polymeric web having first and second opposing, substantially planarweb surfaces. The film further comprises a plurality of threedimensional perforations through the polymeric web. Each threedimensional perforation comprises a hollow protrusion extending from thefirst planar web surface. Each protrusion has an apex, an opening at theapex having a circumference defined, at least in part, by a plurality ofirregularly shaped petals, and an elliptical cross-section parallel tothe planar surface of the web. The elliptical cross-section has aprotrusion axis ratio in a range of 0.65 to 1.35.

The present invention also provides a hydro-formed film. Thehydro-formed film includes a polymeric web having a first substantiallyplanar surface and a second substantially planar surface opposite thefirst substantially planar surface. The hydro-formed film also includesa plurality of three-dimensional micro-apertures extending from thefirst substantially planar surface. The plurality of three-dimensionalmicro-apertures has a mesh count in a range of about 40 to about 75apertures per linear inch. The hydro-formed film has a CompressionSensor Point (CSP) count of at least about 80.

In one contemplated embodiment of the hydro-formed film, each of theplurality of three-dimensional micro-apertures may have an apex and anopening at the apex having a circumference defined, at least in part, bya plurality of irregularly shaped petals.

It is also contemplated that, for the hydro-formed film, each of theplurality of three-dimensional micro-apertures has an ellipticalcross-section parallel to the planar surface of the web, the ellipticalcross-section having a protrusion axis ratio in a range of 0.65 to 1.35.

In a further contemplated embodiment of the hydro-formed film theprotrusion axis ratio may be in a range of about 0.9 to 1.1.

Additionally, the hydro-formed film according to the present inventionmay be formed where the plurality of three-dimensional micro-aperturesis arranged in a two dimensional pattern having three-dimensionalmicro-apertures aligned in a transverse direction of the hydro-formedfilm and staggered in a machine direction of the hydro-formed film.

Still further, the hydro-formed film may have an open area of about 25%.

BRIEF DESCRIPTION OF THE DRAWINGS

The components of the following figures are illustrated to emphasize thegeneral principles of the present disclosure and are not necessarilydrawn to scale. Reference characters designating correspondingcomponents are repeated as necessary throughout the figures for the sakeof consistency and clarity.

FIG. 1 is as depiction of a cross-section view of a single vacuum formedthree-dimensional micro-aperture with male side up;

FIG. 2 is a depiction of a plan view of (looking down on) a vacuumformed three-dimensional micro-aperture with male side up;

FIG. 3 is a schematic view of a segment of a prior art forming screenwith a pattern of round micro-apertures;

FIG. 4 is a micro-scope photograph of three-dimensional micro-aperturesformed on the screen of FIG. 3 by the vacuum forming process;

FIG. 5 is an enlarged micro-scope photograph of a single vacuum formedthree-dimensional micro-aperture formed on the screen of FIG. 3 by thevacuum forming process;

FIG. 6 is a depiction of a cross-section view of a single prior arthydro-formed three-dimensional micro-aperture with male side up;

FIG. 7 is a depiction of a plan view of a prior art hydro-formedthree-dimensional micro-aperture with male side up;

FIG. 8 is a micro-scope photograph of prior art hydro-formedmicro-apertures formed on the screen of FIG. 3 by the hydro-formingprocess;

FIG. 9 is an enlarged micro-scope photograph of a prior art singlehydro-formed three-dimensional micro-aperture formed on the screen ofFIG. 3 by the hydro-forming process;

FIG. 10 is a schematic of an example of a forming screen withmicro-apertures in the shape of this invention;

FIG. 11 is a micro-scope photograph of hydro-formed micro-apertures ofthis invention formed on the screen of FIG. 10 by the hydro-formingprocess;

FIG. 12 is an enlarged micro-scope photograph of a single hydro-formedthree-dimensional micro-aperture of this invention formed on the screenof FIG. 10 by the hydroforming process;

FIG. 13 is a cross-sectional view of a 254 micron segment of 60 meshhydro-formed three-dimensional micro-apertures of prior art which lackthe desired softness being perceived by touch of having only a 60 CSPmesh perception; and

FIG. 14 is a cross-sectional view of a 254 micron segment of 43.5 meshhydro-formed three-dimensional micro-apertures of this invention whichachieve desired softness being perceived by touch of having an 87 CSPmesh perception.

DETAILED DESCRIPTION

An “aperture” is defined as an opening in a planar web, and typicallyfor the primary applications of this invention a web of polymeric film,such that if the web of film was black or otherwise made substantiallyopaque, one can see light passing through the opening. The aperture is athree-dimensional opening with a through hole beginning in the femaleplane of interconnected film (lands) and extending to a second plane atthe apex of the openings. The collection of aperture openings in apattern will thus have an ‘open area’ for the film web per square unit.A ‘Per Square Inch’ area unit will be utilized herein.

A “three-dimensional aperture” is defined as a protruding opening in aweb. The body of the three-dimensional aperture does not entirely lie inthe plane of the web as would a two-dimensional opening. Thethree-dimensional aperture has a base and a distal end, or apex,resulting from the three-dimensional aperture protruding in the Zdirection away from the original base plane of the web and terminatingat its distal end or apex in a second plane. The three-dimensionalaperture at the distal end, or apex, of the protrusion will have anopening with dimensions in the X-Y directions that will be less than thedimensions of the protrusion's base opening on the original base planeof the web. Therefore, most three-dimensional apertures are at leastsomewhat conical or funnel-like.

To be considered ‘three’-dimensional within the terms of this art,generally the distal end plane and the original base plane are spacedapart by an expansion distance, or ‘loft’, of at least about 40 microns.This distance is added to the original web's top-to-bottom Z directiondimension, or web thickness, due to its Z direction expansion caused byforming the protruding three-dimensional apertures.

Within the definitions applicable to this inventive art, it must benoted that three-dimensional apertures formed, for example, by hotneedle penetration or other methods that might create a thickenedgrommet or gathered ends or flaps or hot frictional drag fragments fromthe web into or onto the vicinity of the aperture's perimeter, or otherresults of causing a thickened perimeter such that top-to-bottom Zdirection may have expanded to close to 40 microns, will not beconsidered as belonging within the definition here-in for the term“three-dimensional aperture” since they lack the side-walls of theconical or funnel-like shape.

“Three-dimensional micro-aperture” is defined as a three-dimensionalaperture of fine scale or small dimensions. Fine or small is bestdelimited by mesh. Three-dimensional apertures in a pattern of a meshcount of less than 30 are usually called in the art ‘three-dimensionalmacro-apertures’; hence, three-dimensional apertures in a pattern of amesh of greater than 30 are commonly called in the art‘three-dimensional micro-apertures’. Logically, to fit morethree-dimensional apertures in an aligned length of one inch they mustbe smaller; hence, higher mesh requires the smaller three-dimensionalmicro-apertures. Logically then, mesh counts lower than 30 are used tocomprise patterns of “macro-apertures”. Mathematics and common sensewill guide the selection of mesh combinations of formed films with bothmicro-apertures and macro-apertures.

“Mesh” and/or “mesh count” is a term derived from woven screens, likethe ones used in Curro '518. The number of three-dimensional aperturesthat can be counted within one inch of distance along a line, where thethree-dimensional apertures are aligned in a row, is the mesh count.

“Lands” occur between the three-dimensional apertures because thethree-dimensional aperture's base opening's perimeter must be surroundedby interconnected portions of the web existing in the space between theapertures. The measurement of the space between three-dimensionalapertures comprised of the material of the land defines the ‘landwidth’. These lands between the three-dimensional apertures remaininterconnected in the original plane of the web. The three-dimensionalaperture's openings at their distal end, or apex, have a perimeter aswell; but, there is no interconnected web in this second plane. Thelands only exist in the original base plane of the web from which theapertures protrude. This is also known in the art as ‘female’ side. Theessentially common plane of the aperture's protruding apex at theextended opening is known as the ‘male’ side.

If a film web comprising a pattern of three-dimensional micro-aperturesis to be used as topsheet in an absorptive device, then a pattern ofmacro-apertures may be introduced. In this instance each micro-aperturehas a land width around it, but the pattern of higher mesh countmicro-apertures becomes the land width surrounding the lower mesh countof macro-apertures.

While micro-apertures can reduce surface wetness during use, they arenot by themselves alone sufficient in opening size to move the volumesof fluids introduced to a topsheet; hence, macro-apertures may be addedfor that function while the micro-apertured lands primarily provide fora comfortable tactile impression.

These lands, being interconnected in the original plane of the web,serve to maintain the web's integrity and strength. Narrow land widthsreduce the land area which helps to reduce residual wetness after use inan absorptive device. However, narrow land widths can cause weaker filmstrength, thus one skilled in the art of making three-dimensionalapertured formed films will understand that a balance betweenperformance and strength must be maintained.

Since formed films are formed on forming screens, it is also a factor inthe art that the screen must have a survival integrity. This must beachieved by balancing land width area to opening area and screenthickness so the screen can have a useful and economical life in thevariety of stresses applied by a variety of formed film processes.Furthermore, the various methods to fabricate screens have limitationswhich require the harmonizing of land width, total open area andthickness.

“Pattern” is defined as the geometric array generated by the combinationof three-dimensional apertures and the lands between them. For the mostuseful micro-aperture patterns the aperture shape is round andpositioned in an array formed by 60 degree equilateral triangulation.The aligned apertures are aligned in the TD and thus the equilateraltriangle array cause the apertures in the MD to be staggered. A squarepattern or other patterns known in the art may also be utilized. If theaperture shape is a hexagon, and the land width is held to a commonwidth, then the positioning of hexagons in a pattern naturally resultsin a 60 degree equilateral triangle configuration.

In the broader scope of three-dimensional macro-aperture patternsaperture shape geometries such as triangles, squares, pentagons,hexagons, polygons, circles, ovals, ellipses and the like can beutilized. They are placed in close proximity in an array which usuallyresults in the narrowest possible land width. It is also desirable,whenever possible, that the land width is uniform throughout thepattern. The full extent of combinations of geometries and land widthpossibilities from the formed film art are too vast to itemize.Therefore, only the specifications relating to the inventive patternwill be discussed herein with the belief that one skilled in the art ofmaking three-dimensional apertured films will not require thisexhaustive teaching in order to understand the inventive departure fromthe prior art.

A forming “screen” apparatus within the formed film art is typically acylinder or belt which rotates over a stationary slot. The slot areaprovides the zone where a pressure differential is applied to form thefilm into the pattern of the forming screen's apertures. Screens can beproduced by a variety of methods. These methods include etching,photo-etched and laminated, electroplated, mechanically engraved orlaser engraved from metal or non-metallic materials.

In most types of screens commonly utilized in formed film processes,screen apertures will be aligned in either the X direction or the Ydirection of plane of the web which will be formed to replicate apercentage of the screen's three-dimensional aperture pattern. The Ydirection is typically called the Machine Direction (MD) whereas the Xdirection is called the Transverse Direction (TD). This correlates tothe absorptive device where the MD will be the front waist to back waistdirection and the TD will be the left leg cuff to right leg cuffdirection.

Three-dimensional apertures aligned in the MD are seldom used fortopsheets in the absorptive device art, which comprises the vastmajority of applications for this inventive art.

This is because the aligned three-dimensional apertures create tearinitiation lines and the tearing of topsheets or other layers forabsorptive devices is undesirable. Therefore, it is common in modernabsorptive devices that in the MD of the pattern the three-dimensionalapertures are not aligned but are staggered. In the preferred embodimentof this invention all three-dimensional apertures, both themicro-apertures and macro-apertures, are to be considered as alwaysbeing aligned in the TD and staggered in the MD.

A “Compression Sensor Point” (CSP) is defined as a protrusion in webwhich can be detected by the sensory nerves in the skin when the skincomes into contact with web with some amount of contact pressure andshear motion. Quoting from, Ahr, U.S. Pat. No. 4,463,045, a prior artpatent where protrusions on the film's surface were generated to yield asoft “cloth-like” tactile impression, “Experience has demonstrated thata more cloth-like or fiber-like tactile impression is perceived inmacroscopically expanded three-dimensional plastic webs which meet theaforementioned amplitude criteria whether the surface aberrationscomprise protuberances . . . . This is believed to be due to the factthat in either case the surface of the web is divided into at least twodistinct planes separated from one another by a distance of at least 0.2mils (i.e., 0.0002 inches). In the case of protuberances, it is the topsof the aberrations which contact the observer's skin . . . . Becausesaid division is carried out in a fine microscopic pattern, it isbelieved that only the reduced area of contact with the uppermostsurface of the web and not existence of the pattern is tactilelyperceived.”

Referring further to the prior art, U.S. Pat. No. 4,629,643 to Curro etal. (“Curro '643”), describes tactile function derived frommicro-apertures, and this instance, those made by hydro-forming, asfollows: “The present invention has further relation to such websexhibiting a fine scale pattern of discrete surface aberrations, each ofsaid surface aberrations having its amplitude oriented substantiallyperpendicular to the surface in which said surface aberrationoriginates. A tiny aperture (micro-aperture) is provided substantiallycoincidental with the maximum amplitude of each surface aberration. Thediscontinuity created by the aperture at the peak of each of the surfaceaberrations substantially reduces the resistance to both compression andshear of each individual surface aberration. In addition thevolcano-like edges formed at the periphery of each micro-aperture aretypically in the form of thin, irregularly shaped petals which not onlyreduce the total contact area with the user's skin, but which are alsoeasily deflected when relative movement with the user's skin occurs.Thus micro-apertured webs of the present invention exhibit asignificantly improved tactile response. In particular, the tactileresponse experienced when the user's skin contacts the volcano-likeedges existing at the peak of each aperture surface aberration is a muchsofter sensation than that experienced with similar fine scale patternsof surface aberrations which are entirely unapertured. This differencein tactile impression is most pronounced in shearing actions, i.e., whenthe web's contact with the skin involves lateral movement relative tothe skin rather than simple compressive movement perpendicular to theskin.”

Thus the term CSP, as used herein, is derived from this teaching, thatthe skin's sensory nerves detect the protrusion (aberration) incompression combined with a shear force when contacting the skin. Arequirement, therefore, for the three-dimensional micro-apertured filmof this art, and any related prior art, is that the method's mechanismto cause the expansion also causes some amount of thinning, with someportions fibrillating, around the three-dimensional aperture's distalend opening's perimeter at its apex.

Another requirement for softness is the number of CSP's that can be feltcollectively. Typically hydro-formed micro-apertures of a mesh count of75 to 140, even with a cat-eye aperture shape, are felt collectively.While the high cat-eye ratio causes the aperture to be felt as a singleCSP, at CSP counts above 75 mesh they will yield a collective sensationof softness. However, at CSP counts below 75 with the cat-eye shapecausing the hydro-formed micro-apertures to be felt more individually,they will yield a harsh or rougher tactile impression.

When three-dimensional micro-apertures of 40 to 75 mesh become round,however, as with the vacuum forming process, then the spacing of thediameter of the micro-aperture yields a CSP at both sides of theaperture. This creates a CSP count of about twice the mesh count where a60 mesh pattern of round apertures, for example, actually yields a 120mesh CSP count for soft tactile impression. A 40 mesh yields a CSP countof 80, a 43.5 mesh a CSP count of 87 and so-forth. This is why the roundholes of 40 to 75 mesh from the vacuum formed films feel soft, and whythe hydro-formed films of those mesh counts needed to be changed fromthe cat-eye shape to round in order to feel soft.

As discussed above, the formation of films having three dimensionalapertures is known in the art and the primary methods of producing suchfilms are vacuum-forming and hydro-forming processes. Both of thesemethods produce small surface protrusions having openings at theirapexes. As described in Curro '518 and Curro '643 (the “Curro Patents”),however, hydroforming has the additional benefit that these openingsexhibit petal shaped edges, which, it is believed, enhance the apparentsoftness of the film. It has been found, however, that hydro-formingmethods such as those described by Curro produce ovate apertures havinga longer dimension in the machine direction (MD) than in the transversedirection (TD). This is unlike the vacuum forming process, which can beused to produce virtually circular holes.

The present invention provides a method that produces films withcircular or near-circular three dimensional apertures while maintainingthe tactile advantage of the petal-shaped edges produced byhydro-forming. This is accomplished, at least in part, through the use,in a hydroforming process, of screens having elliptical holes configuredand oriented to produce apertures having a desired ratio of their MD andTD dimensions.

The paragraphs that follow describe the methods and products of theprior art.

Referring now to FIG. 1, a cross-section of a single vacuum formed filmthree-dimensional micro-aperture 10 formed in a generally planar web isshown. Micro-aperture 10 has a male side plane 11 and a female sideplane 12. Aperture 14 is continuous from plane 12 to plane 11 forming athrough-hole. The distance between male side plane 11 and female sideplane 12 is the Z-direction height of the vacuum formed micro-aperturewhich is commonly called the “loft” of the formed film. The vacuumformed film three-dimensional aperture has lands 13 which may beinterconnected to lands of adjacent vacuum formed film three-dimensionalmicro-apertures (not shown) which define the female plane 12. The filmmass of lands 13 continues on to become the sidewall of aperture 14.Note that they continually become thinner with the thinnest portion 15culminating at the aperture's opening at its apex on plane 11. Thethinned portion 15 of the vacuum formed film three-dimensional aperturewill be generally rounded and smooth. Due to the insufficient pressuredifferential of vacuum and the phase change from molten to solid whileforming in the vacuum forming process, the thinned portion 15 does notfibrillate to form the petal-shaped edge described in the Curro Patents.

FIG. 2 shows a plan view of the three-dimensional micro-aperture 10looking down upon the male side plane. Aperture 14 is oriented with theMD top-to-bottom and the TD right-to-left. Lands 13 and the film mass ofthe lands 13 extend up to thinned tip 15 surrounding themicro-aperture's through-hole 14. Through-hole 14, when formed by thevacuum forming process, will generally have substantially equaldimensions in the MD and TD; i.e. an essentially circular shape afterforming. Stresses applied by transferring the web downstream in theMachine Direction may act to stretch and elongate the through-holemicro-aperture a bit; but, as formed, it is virtually circular.

FIG. 3 shows a schematic of a section 30 of a typical forming screenpattern designed to make micro-apertures. For the example used fordescribing this invention, this screen is a 60 mesh screen. Screensection 30 has a 60 degree equilateral triangulated pattern ofmicro-apertures 31 with the aligned micro-apertures aligned in the TDand the MD micro-apertures being staggered. Micro-apertures 31 aresurrounded by lands 32. The land width is substantially equal on allside. For this example land width is 152 microns. TD aperture diameter33 is about 250 microns and MD aperture diameter 34 is equal at about250 microns. The center-to-center spacing 35 of micro-apertures alignedin the TD is 424 microns.

The center-to-center spacing 35 value can be used to determine ‘mesh’.Converting 424 microns to inches yields 0.0167 inches. Dividing 1.0 inchof aligned aperture distance divided by 0.0167 inches ofcenter-to-center spacing yields the 60 mesh count. The 60 mesh screen ofFIG. 3 having the micro-apertures in a 60 degree equilateral trianglearray yields about 4,140 apertures per square inch of forming screen andwill yield about the same value of micro-apertures per square inch forthe films that are formed on this forming screen. The screen open areais about 31%.

FIG. 4 shows a micro-scope photograph of a plan view of a 60 mesh vacuumformed three-dimensional micro-apertured film made from the screen ofFIG. 3. Note the round aperture shapes 41 of the vacuum formed film. Thefilm open area for this vacuum formed micro-apertured film is about24.5%.

FIG. 5 shows an expanded micro-scope photograph of a single vacuumformed film three-dimensional micro-aperture 41 of the vacuum formedfilm of FIG. 4. It has a diameter of about 202 microns in both the MDand TD. The vacuum forming process generally achieves a film aperturediameter that is from about 60% to 85% of the screen's aperturediameter. In this example the film's micro-aperture diameter is about80% of the screen's aperture diameter. Since the round aperture diameterhas virtually equivalent radii in both the MD and TD, that radiuscorresponds to area (πR2); hence, it can also be said that the film'saperture area is also about 80% of the screen's aperture area.

FIGS. 6 and 7 illustrate cross-sectional and plan views of a singlethree-dimensional micro-aperture 60 formed using a hydro-forming methodsuch as that described in the Curro Patents. Micro-aperture 60 has amale side plane 61 and a female side plane 62. Micro-aperture 64 iscontinuous from plane 62 to plane 61 forming a through-hole. Thedistance between male side plane 61 and female side plane 62 is theZ-direction height of the hydro-formed micro-aperture is commonly calledthe “loft” of the formed film. The hydro-formed film three-dimensionalmicro-aperture has lands 63 which are interconnected to lands ofadjacent hydroformed film three-dimensional micro-apertures (not shown)which form the female plane 62. The film mass of lands 63 continues onto become the sidewalls of aperture 64. Note that they continuallybecome thinner with the thinnest tips 65 culminating at the aperture'sopening apex on plane 61. These thinned tips of the hydro-formed filmthree-dimensional micro-apertures will often form fibrillations 66called ‘petals’ in the prior art as shown by the Curro Patents.

The plan view of FIG. 7 shows the three-dimensional micro-aperture 40looking down upon the male side plane 61. Micro-aperture 64 is orientedwith the Machine Direction (MD) top-to-bottom and the TransverseDirection (TD) right-to-left. Lands 63 and the film mass of the lands 63extends up to thinned tip 65 surrounding the micro-aperture'sthrough-hole 64. As will be demonstrated hereafter, the through-hole 64,when formed by the prior art hydro-forming process, will havesubstantially unequal dimensions in the MD and TD; i.e., an ovate or“cat-eye” shape.

FIG. 8 shows a micro-scope photograph of a segment of a prior art 60mesh hydro-formed three-dimensional micro-apertured film made using thescreen of FIG. 3. Note that the film apertures 81 are much smaller andhave a greater MD axis than the TD axis. This is the cat-eye shape. Thecat-eye shape yields an “axis ratio” whereupon the smaller axis isdivided into the larger axis. The illustrated hydro-formed film has anopen area of about 9% and a range of axis ratios from about 1.85 to2.12, even though it was made on the same screen as was thevacuum-formed film shown in FIG. 4.

Cat-eye aperture opening area corresponds to its radii, as well (π[Ra×Rb]). It is known in the art of production of formed films thathydro-forming will only produce a film aperture area with about 25% to45% of the forming screen's aperture area; hence, the hydro-formedapertures are significantly smaller than corresponding apertures of avacuum-formed film produced on the same screen. The reduction in area ispartly due to cat-eye shape of the loss of the TD radius dimension, butalso because the aperture is generally smaller overall.

This narrowing effect of the cat-eye micro-aperture shape is the primarycause for the loss of the desired softness factor for mesh counts fromabout 40 to 75 mesh. This will be discussed in greater detail hereafter,using FIGS. 13 and 14.

It will be understood that the axis ratio of the three dimensionalaperture tends to be constant for cross-sections through the protrusionparallel to the planar surface of the web. This is particularly true ofthe upper portion of the volcano-shaped protrusion up to and includingthe actual perforation at the apex of the protrusion, which is the areathat affects tactile impression when in contact with skin.

FIG. 9 shows an enlarged micro-scope photograph of a single prior artmicro-aperture 81 from FIG. 8 made by the hydro-forming process on thescreen of FIG. 3. It has an MD axis dimension of about 195 microns witha TD axis dimension of about 95 microns. This yields an axis ratio ofabout 2.05. The axis ratio of hydro-formed three-dimensionalmicro-apertures of the prior art will vary depending on a diversity ofscreen patterns and run conditions.

It is known by those of ordinary skill in the art of hydro-forming thatlarger micro-apertures of lower mesh count values will have a lower axisratio due to having more space in the forming screen aperture in whichto form the film aperture. Stating generalizations derived from datawith some distribution, a 40 mesh axis ratio of the prior art process ofhydro-forming micro-apertures may be as low as about 1.45 and a 140 meshaxis ratio can be as high as 2.35.

Additionally, many other variables of the hydro-forming processconditions such as water pressure, water temperature, the rate of screenrotation, the polymer blend being utilized, and the like will createvariation; but, none of these condition manipulations have been found tosuccessfully eliminate the cat-eye shape and its resulting axis ratio.Therefore, the full axis ratio range for prior art hydro-formedthree-dimensional micro-apertures of 40 mesh to 140 mesh is about 1.45to generally about 2.35. In order to achieve the similarly roundapertures of vacuum forming and to gain the advantages of added softnessfrom petals derived from the hydro-forming process, an inventive stepwas required to virtually eliminate the cat-eye shape of hydro-formedmicro-apertures.

The present invention provides a novel variation in the hydroformingprocess. In this variation, the openings in the screen used to form thethree dimensional apertures are specifically tailored to counter thecat-eye problem of previous methods.

As in typical hydroforming processes, the methods of the inventionprovide for continuous disposition of the film on a moving, perforatedforming screen. Forming screens are typically a rotatable hollowcylinder or a belt that is configured so that the perforated wall of thescreen passes over a stationary slot (or slots). After deposition on thescreen, the film is passed beneath a series of aligned high pressurewater nozzles, the pressure to which is supplied by a high pressurewater pump system. The nozzles are designed to deliver a somewhat flatspray pattern and spaced so the edge of the spray pattern of each nozzleslightly overlaps with the edge of the adjacent nozzle so no gaps inapplied pressure exist down the length of the system.

The high pressure water stream causes the film to be pressed into andthrough the openings in the screen, so that they adopt, to some extent,the three dimensional shape of the perforation. As this occurs, the filmis stretched so that it is thinned and eventually ruptures to form aperforation at the apex of the deformation. The film is then removedfrom the screen with the protrusions remaining intact. The film can thenbe further processed (e.g., through the addition of further micro ormacro-perforations) or rolled for storage or transport.

As discussed above, previously used hydroforming methods of this typeproduced elongated cat-eye shaped apertures in the web, the major axisof these apertures being aligned with the direction of motion of thefilm web and the forming screen. The elongate shape is thought to resultfrom the use of regularized (typically circular) screen openings.

The present method differs from previous hydroforming methods in thatthe configuration of the screen perforations are adapted to thecharacteristics of the process and the film material so as to reduce oreliminate the elongation effect. In general, this involves making thescreen openings elliptical (or similar ovate shape) with their minoraxes aligned in the machine direction and their major axes aligned inthe transverse direction. The exact ratio of the major to minor axis isa function of the material, speed of the manufacturing line, waterpressure and temperature, etc.

The water temperature is typically elevated to 180° F. to soften, butnot melt, the film; but temperatures within the range of 120-200° F. canalso be functional. The water nozzles are placed about 4-5 inches awayfrom the rotating screen cylinder, but distances of 2-10 inches may alsobe applied. The film web caliper can range from 12-70 microns inthickness with common gauges ranging from 22-24 microns. The web can becomprised of a variety of olefin polymers in monolayer or coextrudedmultiple layers.

The methods of the invention can be used with films formed from anysuitable polymer. Particularly suitable polymers include, but are notlimited to, polyethylene, low density and ultra low densitypolyethylene, polypropylene, linear low and medium density polyethylene,metallocenes, block copolymers, vinyl acetate copolymers, and variouselastomers. These can be used either blended into monolayer films orextruded independently or formed in coextruded films having two layersto five layers or more as one skilled in the art of film extrusion maydesign to meet a variety of film attribute requirements.

Referring now to FIG. 10, a portion of an exemplary forming screen 100for use in the methods of the invention is shown. The exemplary screen100 is a 43.5 mesh screen. The apertures 101 of screen 100 have a majoraxis 103 greater than the minor axis 104 by a factor (i.e., the axisratio) of about 1.35. Screen 100 has apertures 101 surrounded by lands102. The land width is preferably equal on all side. For this exampleland width is 102 microns. TD aperture diameter 103 is about 483 micronsand MD aperture 104 is about 345 microns. The center-to-center spacing105 of apertures aligned in the TD is 585 microns.

While the axis ratio of the illustrated example is 1.35, it will beunderstood by those of ordinary skill in the art that screens with axisratios from about 1.15 to 2.50 can be utilized.

These variations may be necessary for various mesh counts, patternarrays, or polymer blends for mono-layer films and/or coextruded films.Coextruded films can utilize from 2 to 5 layers effectively, whereuponthe features of each layer are designed for specific functions in eitherhydro-forming aperture formation or end use requirements or both.

The center-to-center spacing 105 can be used to determine ‘mesh’.Converting 585 microns to inches yields 0.023 inches. 1.0 inch ofaligned aperture distance divided by 0.023 inches of center-to-centerspacing yields about a 43.5 mesh count. The 43.5 mesh screen of FIG. 10has the apertures aligned in the TD and in a staggered array in the MD.With the uniform land width this yields about 2,414 apertures per squareinch of forming screen. Whereupon the screen has 43.5 apertures per inchin the TD and about 55.5 apertures in the MD, then 43.5×55.5=2,414apertures per square inch. The screen open area is around 50%. Whenhydro-formed micro-apertured film is produced on forming screen 100 ofFIG. 10 it will yield about the same value of apertures per square inch,depending on machine direction draws which may distort the film packingthe apertures a bit closer in the TD.

To create this inventive screen of a preferred embodiment with a highopen area of about 50% and a relatively high count of apertures persquare inch while also having narrow land widths of 102 microns, formingscreen 100 of FIG. 10 was made by the photo-etch and laminate method astaught by U.S. Pat. No. 5,562,932 to Rieker, incorporated herein byreference, with exception that the laminated layers are stackedvertically versus at an offset angle. Another preferred technique formaking a forming screen as required for this invention is the methoddisclosed by U.S. Pat. No. 8,460,778 to Thomas et al., incorporatedherein by reference, of laser engraving thermoset materials like rubber.A finish of a nickel plated coating over the rubber screen enhances thestrength and thermal properties of these rubber laser engraved screens.Laser engraving a metal screen may also be plausible, as are any of thescreen making methods if properly manipulated.

FIG. 11 shows a portion of the 43.5 mesh hydro-formed film ofthree-dimensional micro-apertures 111 made by the hydro-forming processon the inventive screen of FIG. 10. Note that the apertures arevirtually round. The open area of this inventive hydro-formedthree-dimensional micro-apertured film is about 25%; hence, thehydro-forming process has created apertures 111 of about 50% of the sizeand open area of the forming screen apertures; and exceptionally, theyhave no discernable cat-eye shape but rather appear to be virtuallyround with essentially equivalent MD and TD axes.

FIG. 12 is an expanded micro-scope photograph of a single micro-aperture111 from FIG. 11. The aperture 111 has an MD axis of about 292 micronsand a TD axis of about the same measure of 292 microns. That yields around hole with an axis ratio of 1.00. A few of the apertures shown inFIG. 11 have an MD axis of about 292 microns with a TD axis of about 255microns yielding a significantly reduced, virtually round, axis ratio ofabout 1.15. Although measurements were taken from a much larger numberof apertures than is shown in FIG. 11, no measurement made by thismethod has given a micro-aperture axis ratio greater than 1.35.

As mentioned earlier for the prior art of vacuum forming, which formsessentially round apertures, vacuum formed three-dimensionalmicro-apertures can achieve a significant degree of softness in meshcounts from about 40 to 75, but lack ‘superior’ softness because theylack the feature of fibrillated petals.

It was shown in the prior art that a 60 mesh films of vacuum formedthree-dimensional micro-apertures are successfully marketed today asbeing soft and that hydro-formed three-dimensional micro-apertured filmsof the prior art of 100 mesh have had market success for softness.However, a 60 mesh variety of hydro-formed micro apertured film, forexample, lacks the needed softness. FIG. 13 will be utilized for anexplanation of that observation and FIG. 14 will show why creating ahydro-formed three-dimensional micro-aperture with a round shape, versusthe cat-eye shape, is an inventive step which makes the hydro-formedmicro-apertured film feel soft.

Referring now to FIG. 13 we see a cross-section of a segment of priorart hydro-formed three-dimensional micro-apertured film 130. The segment130 is about 254 microns in length and comes from a 60 mesh patternscreen. Segment 130 has a male side plane 131 and a female side plane132. Micro-apertures 134 are continuous from plane 132 to plane 131forming through-holes. The distance between male side plane 131 andfemale side plane 132 is the Z-direction height of the hydro-formedapertures which is commonly called the “loft” of the formed film. Thehydro-formed film three-dimensional micro-aperture has lands 133 whichare interconnected to the lands of the adjacent hydro-formed filmthree-dimensional micro-apertures which form the female plane 132. Thefilm mass of lands 133 continues on to become the sidewalls of aperture134. Note that they continually become thinner with the thinnest tips135 culminating at the aperture's opening apex on plane 131. Thesehydro-formed film three-dimensional micro-apertures have a cat-eye shapeand the narrow axis width of aperture 134 shown in FIG. 13 is in the TDaxis width, left to right in FIG. 13. The major axis in the MD ispointing away from the viewer of FIG. 13. Being hydro-formed somemicro-apertures may have petals 146, but their softness effect isnullified by other overwhelming factors.

As defined above, a protrusion that yields sensory recognition by theskin's nerves is a “Compression Sensor Point” (CSP). It has been shownin several prior art teachings (some noted above) that the CSP'sresulting from micro-apertures should be closely packed because if theCSP's are too far apart they are sensed individually and the sensationmoves toward being harsh or rough. To best detect the sensation ofsoftness the skin must detect a collective effect of protrusion tipsthat can compress and bend during a skin contact moment. The thinnedopenings at their apex, and an occasional petal, serve to provide thecompression and bending mechanisms of a CSP that best provide for thesensation of softness provided they are within the range of CSP countsthat yield softness. The soft CSP count where softness first occurs isgenerally believed to be about 80.

The primary factor to note in FIG. 13 is that since the apertures have asignificant cat-eye shape with a high axis ratio, being narrow versusspread out, they become “individual” CSPs 137. With a center-to-centerspacing 138 of 424 microns, these CSPs 137 are spaced apart at a CSPcount of 60 mesh such that the skin can feel them as a single CSP unitversus as a collective of multiple units; and, as shown in the priorart, since the CSP count is below 80, this sensation robs the softnesstactile impression, and rather, is moving toward a harsh or a roughsensation.

When the vacuum forming process produces round three-dimensionalmicro-apertures in the same 60 mesh count, the CSP becomes the side-wallon either side of the aperture due to the widening of the distancebetween the sidewalls. Thusly, a 60 mesh vacuum formed three-dimensionalmicro-apertured film will produce CSPs at about a about 120 mesh and ittherefore feels soft, like the 100 mesh hydro-formed feels soft, as bothCSP counts are above the minimum count of about 80 for softness.

Referring now to FIG. 14 segment 140 of the inventive hydro-formedthree-dimensional micro-apertured film is shown. This segment 140 lengthis also about 254 microns. Film segment 140 has a male side plane 141and a female side plane 142. Micro-apertures 144 are continuous fromplane 142 to plane 141 forming a through-hole. The distance between maleside plane 141 and female side plane 142 is the Z-direction height ofthe hydro-formed micro-apertures which is commonly called the “loft” ofthe formed film. The hydro-formed film three-dimensional micro-apertureshave lands 143 that are interconnected to lands of adjacent hydro-formedfilm three-dimensional micro-apertures which form the female plane 142.The film mass of lands 143 continues on to become the sidewalls ofaperture 144. Note that they continually become thinner with thethinnest tips 145 culminating at the aperture's opening apex on plane141. Some thinned tips 145 have petals 146.

Micro-apertures 144 have a TD aligned center-to-spacing 148 of about 585microns yielding a mesh count of around 43.5 mesh. Micro-apertures 144have a MD and TD diameter of about 292 microns; and, since the CSPs 147are in this case the thinned side-wall of micro-aperture 144, the CSPspacing, both across the aperture opening 149 and between apertures149′, is about 292 microns, which is much closer together. At 43.5 meshthe CSP 147 count of this inventive film is about 87 which is above theminimum value of 80 for softness. With the addition of the hydro-formedpetals 146 greater softness may be achieved. Additionallymicro-apertured films of greater than 15% open area will provide for theadequate removal of residual fluids after use. Therefore the preferredembodiment of this inventive film depicted in FIGS. 11 and 14 having 25%open area should provide for sufficient dryness if utilized as atopsheet.

This invention therefore provides a hydro-formed three-dimensionalmicro-apertured film soft enough, with enough open area to enhanceremoval of residual fluids to be useful as, but not limited to, atopsheet in absorptive devices such as feminine napkins, panty liners,baby diapers, adult diapers, incontinence inserts, bandages and thelike, particularly when a pattern of macro-apertures are added to it.

It will be readily understood by those persons skilled in the art thatthe present invention is susceptible to broad utility and application.Many embodiments and adaptations of the present invention other thanthose herein described, as well as many variations, modifications andequivalent arrangements, will be apparent from or reasonably suggestedby the present invention and foregoing description thereof, withoutdeparting from the substance or scope of the invention.

Accordingly, while the present invention has been described here indetail in relation to its preferred embodiment, it is to be understoodthat this disclosure is only illustrative and exemplary of the presentinvention and is made merely for the purposes of providing a full andenabling disclosure of the invention. Many modifications to theembodiments described above can be made without departing from thespirit and scope of the invention. Accordingly, the foregoing disclosureis not intended to be construed or to limit the present invention orotherwise to exclude any other such embodiments, adaptations,variations, modifications and equivalent arrangements.

What is claimed is:
 1. A hydro-formed film comprising: a polymeric webhaving a first substantially planar surface and a second substantiallyplanar surface opposite the first substantially planar surface; and aplurality of three-dimensional micro-apertures extending from the firstsubstantially planar surface, the plurality of three-dimensionalmicro-apertures having a mesh count in a range of about 40 to about 75apertures per linear inch, wherein the hydro-formed film has aCompression Sensor Point (CSP) count of at least about
 80. 2. Thehydro-formed film according to claim 1, wherein, each of the pluralityof three-dimensional micro-apertures has an apex and an opening at theapex having a circumference defined, at least in part, by a plurality ofirregularly shaped petals.
 3. The hydro-formed film according to claim1, wherein each of the plurality of three-dimensional micro-apertureshas an elliptical cross-section parallel to the planar surface of theweb, the elliptical cross-section having a protrusion axis ratio in arange of 0.65 to 1.35.
 4. The hydro-formed film according to claim 3,wherein the protrusion axis ratio is in a range of about 0.9 to 1.1. 5.The hydro-formed film according to claim 1, wherein the plurality ofthree-dimensional micro-apertures is arranged in a two dimensionalpattern having three-dimensional micro-apertures aligned in a transversedirection of the hydro-formed film and staggered in a machine directionof the hydro-formed film.
 6. The hydro-formed film according to claim 1,wherein the hydro-formed film has an open area of about 25%.